Induction charging unit and energy transfer system with same

Abstract

An induction charging unit for an energy transfer system may include a cooling device, at least one electrical power component, and a clamping device. The cooling device may define a mounting face and may be configured to dissipate heat energy. The at least one electrical power component may be clamped to the mounting face of the cooling device via the clamping device.

1 . An induction charging unit for an energy transfer system, comprising:
 a cooling device defining a mounting face and configured to dissipate heat energy;   at least one electrical power component; and   a clamping device;   wherein the at least one electrical power component is clamped to the mounting face of the cooling device via the clamping device.   
     
     
         2 . The induction charging unit according to  claim 1 , further comprising a printed circuit board, wherein:
 the printed circuit board is disposed opposite the cooling device in a direction of a vertical axis perpendicular to the mounting face;   the at least one electrical power component is disposed in the direction of the vertical axis between the printed circuit board and the cooling device, and is arranged on the printed circuit board; and   at least one of:   the clamping device engages through an opening of the printed circuit board; and   the clamping device is arranged on a side of the printed circuit board facing away from the cooling device.   
     
     
         3 . The induction charging unit according to  claim 2 , wherein at least one of:
 the opening completely penetrates the printed circuit board in the direction of the vertical axis; and   the opening and the at least one electrical power component are disposed on an alignment line.   
     
     
         4 . The induction charging unit according to  claim 1 , wherein the clamping device includes at least one of i) at least one spring clamp and ii) at least one spring clamp device. 
     
     
         5 . The induction charging unit according to  claim 4 , wherein:
 the clamping device includes the at least one spring clamp device; and   the at least one spring clamp device includes:
 a base body that is immobile with respect to the cooling device; 
 a clamping element that defines a clamping element center axis in a main direction of expansion of the clamping element; and 
 an adjusting spring arranged on the clamping element. 
   
     
     
         6 . The induction charging unit according to  claim 5 , wherein at least one of:
 the adjusting spring tensions the clamping element axially with respect to the clamping element center axis onto the at least one electrical power component such that the at least one electrical power component is clamped onto the mounting face of the cooling device via the clamping element;   the adjusting spring is arranged on a side of the printed circuit board facing away from the cooling device;   the clamping element is mounted on the base body such that the clamping element is adjustable longitudinally in a direction of the clamping element center axis;   the clamping element center axis extends parallel to a vertical axis perpendicular to the mounting face; and   the clamping element engages through an opening in a printed circuit board.   
     
     
         7 . The induction charging unit according to  claim 5 , wherein the adjusting spring is one of:
 a pressure spring that is supported on the base body and the clamping element, and that is guided on the clamping element; and   a leaf spring that is integrally formed with the base body.   
     
     
         8 . The induction charging unit according to  claim 5 , wherein the clamping element is connected to the at least one electrical power component. 
     
     
         9 . The induction charging unit according to  claim 5 , wherein:
 the at least one spring clamp device further includes a holding device defined by a plurality of tie rods fixed to the cooling device, the base body connectable to the cooling device in at least one of a releasable, a form-fitting, and a force-fitting manner via the plurality of tie rods; and   at least one of:
 the plurality of tie rods include a plurality of form-fitting contours via which the base body is releasably fixable to a respective tie rod of the plurality of tie rods in at least one of a form-fitting and a force-fitting manner; 
 the base body is fixable to a respective tie rod of the plurality of tie rods in at least one of a releasable, a form-fitting, and a force-fitting manner via a plurality of fastening elements; 
 the plurality of tie rods are fixed to the cooling device in a material-fitting manner; and 
 the plurality of tie rods at least one of pass through and engage around an outer edge of a printed circuit board. 
   
     
     
         10 . The induction charging unit according to  claim 1 , further comprising a coupling layer arranged in a direction of a vertical axis perpendicular to the mounting face of the cooling device between the mounting face and a flat component face defined by the at least one electrical power component, wherein at least one of:
 the coupling layer is contacted with the at least one electrical power component;   the coupling layer is in contact with the cooling device;   the coupling layer is fixed to the component face of the at least one electrical power component;   the coupling layer is releasably clamped in contact with the mounting face;   the coupling layer is composed of a ceramic material;   the coupling layer has a material thickness in the direction of the vertical axis of 0.2 mm to 2 mm;   the coupling layer has a thermal conductivity of 0.2 W/mK to 50 W/mK;   the coupling layer has an electrical breakdown strength of at least 500 V DC; and   the coupling layer is composed of a composite material and has at least one of a material thickness of 0.05 mm to 1 mm in the direction of the vertical axis, a thermal conductivity of 0.1 W/mK to 5 W/mK, and an electrical breakdown strength of at least 200 V DC.   
     
     
         11 . The induction charging unit according to  claim 10 , further comprising a fixing layer arranged in the direction of the vertical axis between and connecting the coupling layer and the component face of the at least one electrical power component, wherein at least one of:
 the fixing layer is thin in the direction of the vertical axis with respect to the coupling layer;   the fixing layer is composed of a thermally conductive adhesive material;   the fixing layer has a material thickness of 5 μm to 150 μm in the direction of the vertical axis; and   the fixing layer has a thermal conductivity of 0.2 W/mK to 50 W/mK.   
     
     
         12 . The induction charging unit according to  claim 5 , wherein the clamping element is connected to the at least one electrical power component in at least one of a form-fitting, a force-fitting, and a material-fitting manner. 
     
     
         13 . The induction charging unit according to  claim 5 , wherein the clamping element electrically insulates the at least one electrical power component with respect to the cooler device. 
     
     
         14 . The induction charging unit according to  claim 10 , further comprising a contact layer arranged in the direction of the vertical axis between the coupling layer and the mounting face of the cooling device, the contact layer configured to make contact between the coupling layer and the cooling device, wherein at least one of:
 the contact layer is a film of heat transfer oil;   the contact layer is non-adhesive; and   the contact layer is non-hardening.   
     
     
         15 . An energy transmission system for inductively charging a battery-powered electric vehicle with electrical energy, comprising:
 the induction charging unit according to  claim 1 ; and   a counter-induction charging unit arranged on the vehicle;   wherein the induction charging unit and the counter-induction charging unit are configured to transfer energy in a contactless manner via magnetic coupling.   
     
     
         16 . The induction charging unit according to  claim 2 , wherein the printed circuit board is arranged parallel to the mounting face. 
     
     
         17 . The induction charging unit according to  claim 2 , wherein:
 the opening extends completely through the printed circuit board in the direction of the vertical axis; and   the opening and the at least one electrical power component are disposed on an alignment line extending parallel to the vertical axis.   
     
     
         18 . The induction charging unit according to  claim 2 , wherein the clamping device is a spring clamp device including:
 a base body that is immobile with respect to the cooling device;   a clamping element having a main direction of expansion and electrically insulating the at least one electrical power component with respect to the printed circuit board and with respect to the cooler device; and   an adjusting spring arranged on the clamping element.   
     
     
         19 . The induction charging unit according to  claim 18 , wherein the spring clamp device further includes a plurality of tie rods releasably connected to the base body and fixed to the cooling device via a welded connection. 
     
     
         20 . The induction charging unit according to  claim 8 , wherein the clamping element is glued to the at least one electrical power component.